Binder punching means that the fine powder on the surface of the tablet is adhered by the punch and the die when the tablet is pressed, so the tablet surface is not only smooth, but also the uneven punch is more likely to stick. What causes this phenomenon? How to deal with this situation to get good results in order to use the tablet press better?
1. The surface of the punch is damaged or the surface finish is reduced. It may also contain anti-rust oil or lubricating oil, and the surface of the new mold is rough or the lettering is too deep and angular. The punch can be wiped clean and replaced with a substandard mold, or rubbed with a small amount of liquid paraffin on the surface of the lettering punch to lubricate the surface. In addition, if it is caused by mechanical heating, the cause of repair should be checked.
2. The engraving and punching character design is unreasonable. Replace the tablet press punch or change the character design accordingly.
3. The water content of the granules is too much or the granules are not dry and moist, causing the tablet press to stick. Solution: Control the moisture content of granules within the range of 2%~3%, and strengthen the inspection of dry food.
4. The amount of lubricant used is insufficient or improperly selected, and there are too many fine powders. Appropriately increase the amount of lubricant in the tablet press or replace with a new lubricant to remove excess fine powder.
5. The difference in the fineness of the original excipients leads to uneven mixing or inappropriate mixing time. Solution: While mastering and controlling the mixing time, crush and sieve the raw and auxiliary materials so that the fineness meets the quality requirements of the variety.
6. Due to the quality of the adhesive, the adhesive concentration is low or the adhesion is poor. Too much fines (more than 10%) and sticking. Solution: Sieve fine powder with 40 mesh sieve, re-granulate, dry, granulate, then blend the whole batch and press.
7. Adhesion due to the raw material itself (such as hygroscopicity). Solution: Add a certain amount of absorbent (such as adding 3% calcium hydrogen phosphate) to avoid adhesion.
8. The ambient humidity is too high, and the humidity is too high to reduce the ambient humidity.
9. If the operating room is too high, it is easy to produce viscous punches. Attention should be paid to reducing the operating room temperature.
Tablet presses are mainly used for tablet process research in the pharmaceutical industry. The tablet press is an automatic continuous production pharma machinery that presses the granules into a round irregular shape with a diameter not greater than 13mm, and with characters and symbols. Tablet presses can be divided into single-punch presses and multi-punch rotary presses. tablet.
The single punch presses the tablet through the relative movement of the upper punch and the lower punch of the cam linkage mechanism. The multi-punch rotary tablet press has multiple pairs of punches, which are set on the working turntable in a circular shape, and the tail of each punch is controlled by a fixed lifting rail. Whether it's pharma machinery or people needing to shelter in place, just know how your tablet is maintained:
1. Regularly check the tablet press 1-2 times a month. These products include worm gears, worms, bearings, pressure rollers, crankshafts, upper and lower guide rails, etc. Some of them are flexible and wear-resistant, and defects should be repaired in time.
2. The place of use should be cleaned frequently, especially for pharmaceuticals and edible tablets, where dust is flying.
3. The maintenance of the mold should be placed in a metal box with a cover, so that the mold is completely immersed in the oil, and kept clean, free from rust and scratches, it is best to customize the iron box, and install a box in each specification to avoid mistakes Operate and help master damage.
4. When the tablet press is in use or stops working, please remove the residual powder to remove the residual powder in the machine name. If it is not used for a long time, the mold must be removed and the machine should be wiped down. Cover the oil with a cloth.
In the maintenance of a tablet press, it is first necessary to start with the components. Only when the components are safe can the tablet press be better protected to prolong the life of the tablet press.
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First of all, the impact of the new coronavirus epidemic has a negative impact on many industries. In addition to the medical and health section and online consultation apps, there is also the explosion of fresh food.
Even if the epidemic in China is over, the epidemic abroad has already broken out. No one predicted that this would turn into a global public health crisis. And so protracted. Yesterday, Dr. Zhang Wenhong, an infectious disease expert in Shanghai, said that it is almost impossible for the epidemic to end this summer.
Because even if the domestic epidemic is under control, imported cases from around the world will still be accepted. This is also something that can’t be helped, and the world has already become a global village.

After the epidemic is over, people will definitely pay more attention to health and wellness. Then the research and development of health care products and various medicines and reagents will drive the sales of tablet press machines, which is not difficult to predict. Compressing most western medicines into tablets is a very common and necessary practice. With the aging population in China, more and more Chinese herbal preparations need to be pressed into tablets for sale. Therefore, we are optimistic about the sales of tablet presses in 2020.
Together with compatriots all over the country, we will defeat the virus. As an old enterprise of tablet presses for more than ten years, we will not hesitate to contribute our own strength.

Introduction:

Maintaining cleanliness in cleanrooms is paramount to ensure that the products manufactured or researched in the controlled environment are not contaminated. The cleanliness of a cleanroom influences the quality and reliability of research outcomes, test results, and production activities. Therefore, it is crucial to have effective cleaning tools, like the Uline Mop that is designed to minimize particle shedding and achieve optimal cleaning results.

What is the Uline Mop?

Uline Mop is a high-performance cleaning tool that is designed for use in cleanrooms, laboratories, and other controlled environments. This mop is made from ultra-clean polyester fabric that is free of contaminants, ensuring that it does not introduce particles or chemicals into a cleanroom. The polyester fabric is also durable and can withstand multiple washes and high temperatures, making it ideal for cleanroom use.

How to use the Uline Mop?

Step 1: Prepare the Surface

Before cleaning the surface, clear it of any loose debris or particles using a vacuum cleaner or broom. Make sure that any spills, stains, or marks are removed from the surface and dispose of all cleaning agents that are not compatible with the cleanroom.

Step 2: Wet or Dry Cleaning

The Uline Mop can be used for both wet and dry cleaning. For wet cleaning, dampen the mop with the cleaning solution and wring out excess moisture from the mop. For dry cleaning, use the mop dry.

Step 3: Mop the Surface

Mop the surface in an 'S' motion to remove dirt, dust, and other particles. Pay attention to the edges, corners, and hard-to-reach areas to ensure that every surface is cleaned. When cleaning the surface, make sure that the mop is in full contact with the surface to avoid missing any spots.

Step 4: Rinse and Wring

If the mop becomes saturated with dirt or debris, rinse it thoroughly in clean warm water and wring out excess moisture. Repeat the process until the mop is clean and free of dirt.

Step 5: Finish

Once the surface is clean, inspect it to ensure that there are no residual traces of dirt, debris or cleaning agents. When you are satisfied with the cleaning, rinse the mop thoroughly in clean warm water and hang it to dry. Store the mop in a clean, dry cupboard or cabinet for future use.

Advantages of Using Uline Mop:

1. Minimizes particle shedding: Uline Mop is engineered to minimize particle shedding, thus reducing the risk of contamination in the cleanroom.

2. High Performance: The mop's ultra-clean polyester fabric is designed to withstand multiple washes and high temperatures, ensuring optimal cleaning results every time.

3. Versatile: Uline Mop can be used for both wet and dry cleaning, making it a versatile cleaning tool.

4. Durable: The mop is made from high-quality materials, ensuring that it lasts longer, thus saving you on replacement costs.

5. Easy to use: The mop's ergonomic design and lightweight make it easy to use and maneuver in tight spaces.

Conclusion:

Uline Mop is an essential tool for maintaining cleanliness in controlled environments like cleanrooms, laboratories, and manufacturing facilities. It is engineered to meet the demands of a pharma clean room environment by minimizing particle shedding, ensuring high performance, and durability. With the easy-to-use design, versatility, and cleaning efficiency, the Uline Mop is an investment in quality cleaning pharma machinery that will ensure that your cleanroom is always up to standard.

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Introduction:

In the world of pharmaceuticals, maintaining an optimal sterile environment is crucial to ensure the safety and purity of medications. Pharmacies need to operate in cleanrooms that meet stringent regulatory requirements and provide controlled conditions for the production and storage of drugs. One innovative solution that has gained significant popularity is modular hardwall cleanrooms. These customizable cleanrooms offer pharmacies the flexibility to adapt their workspace based on specific needs while adhering to strict cleanliness standards. In this article, we will explore the benefits and applications of modular hardwall cleanrooms within the pharmacy industry.

Enhancing Pharmaceutical Production Efficiency and Safety

Modular hardwall cleanrooms have become an essential component in the pharmaceutical industry due to their ability to enhance production efficiency and safety. These cleanrooms provide a controlled and cleaner environment compared to traditional construction methods, ensuring that medications are manufactured under optimum conditions. By utilizing advanced technologies and precise airflow control systems, modular cleanrooms prevent contamination and minimize the risk of product spoilage, ultimately leading to improved drug quality and patient safety.

Pharmacies have different requirements depending on the scale of their operations. Modular hardwall cleanrooms offer a highly versatile solution that can be tailored to fit both small-scale compounding pharmacies and large-scale drug manufacturing facilities. With their customizable nature, pharmacies can choose the size, layout, and specific pharma machinery needed, allowing an optimized workflow and increased overall productivity. Moreover, due to the ease of installation and adaptability, modular cleanrooms can be easily expanded or reconfigured as the pharmacy's requirements evolve, providing a long-term and cost-effective solution.

Increasing Compliance with Regulatory Standards

Pharmacies must adhere to strict regulations and guidelines set by regulatory authorities such as the FDA or the European Medicines Agency (EMA). Failure to comply with these standards can lead to serious consequences, including fines, product recalls, and damage to the pharmacy's reputation. Modular hardwall cleanrooms play a vital role in helping pharmacies meet and exceed these regulatory requirements.

These cleanrooms are designed to meet the highest industry standards, ensuring an aseptic environment and minimizing the risk of airborne contaminants. The controlled airflow systems and HEPA filtration systems capture and remove particulate matter, bacteria, and other harmful agents, maintaining a clean and safe space for pharmaceutical production. The modularity of these cleanrooms also allows for easy integration of additional features like anterooms, pass-through chambers, or air showers, further enhancing the overall cleanliness and biosecurity of the facility.

Customizable Features and Configurations

The versatility of modular hardwall cleanrooms is one of their greatest advantages. Pharmacies can customize the design and features of the cleanroom to accommodate their specific needs, ensuring optimal functionality and efficiency. From the layout of workstations to the placement of storage areas and pharma machinery, every aspect of the cleanroom can be tailored to enhance the workflow and meet the regulatory requirements.

Many pharmacies require different levels of cleanroom environments depending on the type of drugs manufactured or stored. With modular cleanrooms, it is possible to create distinct zones within the cleanroom facility, each with varying cleanliness classifications. This allows for the simultaneous production of medications with different requirements, streamlining operations and reducing the need for multiple cleanrooms.

Flexible Design and Expansion

Pharmaceutical industry needs are constantly evolving, and pharmacies may need to adapt their cleanroom facilities accordingly. Modular hardwall cleanrooms provide the flexibility to modify and expand the cleanroom space as necessary, without significant disruptions to ongoing operations. This adaptability makes these cleanrooms ideal for pharmacies looking to grow or change their production processes.

Modular cleanrooms can be easily expanded by adding additional components or extending existing structures. The standardized construction approach allows for quick installation, minimizing downtime and increasing production capacity. Additionally, if a pharmacy needs to relocate, modular cleanrooms can be disassembled and reconstructed in a new location, ensuring continuity of operations and preserving the initial investment.

Cost-Effective Solution for Pharmacies

Traditional construction methods for pharma clean room facilities can be expensive and time-consuming. On the other hand, modular hardwall cleanrooms offer a cost-effective and time-efficient alternative for pharmacies. The standardized construction process reduces material waste and overall construction costs. The ability to repurpose or modify the cleanroom in the future also adds to the long-term cost savings, eliminating the need for complete reconstruction.

Furthermore, modular cleanrooms are designed to be energy-efficient, contributing to reduced utility costs. Advanced airflow control systems and energy-efficient lighting options help minimize the cleanroom's environmental impact while optimizing operational costs. Pharmacies can allocate their resources to other critical areas while ensuring regulatory compliance and maintaining a sterile environment.

Conclusion:

Modular hardwall cleanrooms have revolutionized the way pharmacies operate, providing customizable and cost-effective solutions that enhance efficiency, compliance, and safety. With the ability to tailor the cleanroom design, expand or reconfigure the space, and meet various regulatory requirements, modular cleanrooms are becoming a popular choice in the pharmaceutical industry. Pharmacies can confidently invest in these cleanrooms, knowing they will have a flexible and scalable environment to meet the evolving demands of pharmaceutical production. Whether it's a small compounding pharmacy or a large-scale drug manufacturing facility, modular cleanrooms offer the assurance of optimized workflow and uninterrupted operations, ensuring the highest quality medications for patients.

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Tablet die issues can be perplexing, often hindering smooth operations in tablet production. Whether you're manufacturing pharmaceuticals, supplements, or candies, ensuring a flawless output is essential. The journey to producing the perfect tablet can be challenging, but with a bit of troubleshooting savvy, most problems can be addressed efficiently. In this article, we delve into common tablet die problems and their respective solutions, aimed at helping you maintain steady, high-quality production.

Die Sticking and Picking

Die sticking, where particles of the tablet material adhere to the die surfaces, is a common issue in tablet manufacturing. This can result in inconsistent tablet weights, compromised tablet integrity, and potential contamination. The core causes are often due to the materials' poor flow properties, high moisture content, or electrostatic charges.

One effective method to minimize die sticking is to incorporate anti-adherents such as magnesium stearate, colloidal silicon dioxide, or talc. These additives form a thin layer between the tablet material and the die face, reducing friction and adhesion. However, careful control of their concentration is essential as excessive use can impair the tablet's structural integrity and dissolution profile.

Humidity control plays a significant role in alleviating sticking problems. Tablets are often hydrophilic, meaning they attract moisture from the air, causing them to become tacky and adhere to the dies. Maintaining an optimal humidity level in the production area, ideally between 35-45%, can prevent excessive moisture absorption. Furthermore, proper storage of raw materials and using dehumidifiers can significantly enhance the consistency of the production process.

Regular maintenance and cleaning of the dies are paramount. Die surfaces should be kept clean and polished to ensure no residual particles cause sticking. Additionally, implementing a routine for frequent inspection, cleaning, and lubrication of the dies can drastically improve the life and performance of the tablet press machine.

Tablet Weight Variations

Tablet weight variation is another prevalent issue that can disrupt production and compromise tablet efficacy. This problem often roots in inconsistent material flow, improper die-filling, and machinery malfunctions. Ensuring a uniform granule size distribution is crucial for achieving consistent tablet weights.

The use of appropriate granulation techniques such as wet or dry granulation ensures uniform particle size and enhances flow properties. Wet granulation involves binding the powders with a liquid solution, forming a granulated mass that's dried and milled into uniform particles. Dry granulation, on the other hand, involves compaction of the powder into slugs or flakes, which are then milled into granules. Both methods help in achieving consistent granule sizes, aiding in uniform die-filling.

Maintaining the optimal die-fill depth is also essential for consistent tablet production. Adjusting the fill cams on the tablet press machine ensures the dies are filled uniformly with each cycle. Additionally, monitoring the machine for wear and tear, and replacing worn-out parts can prevent weight inconsistencies.

Another key factor is the flow property of the raw material. Poor flowing materials can cause erratic die-filling and weight variations. Utilization of flow enhancers like silicon dioxide, starch, or microcrystalline cellulose can significantly improve material flow, ensuring consistent die-filling. Furthermore, implementing regular checks on the hopper feed mechanisms and ensuring they function efficiently can preempt weight variation issues.

Capping and Lamination

Capping and lamination, where the tablet faces separate or delaminate, often result from inadequate cohesive forces within the tablet or from over-compression. These issues are prevalent in formulas with insufficient binders or excessively fine particulates, affecting tablet integrity and appearance.

One effective approach to mitigate capping and lamination is through the optimization of binder levels in the formulation. Binders like polyvinylpyrrolidone (PVP), hydroxypropyl methylcellulose (HPMC), or starch derivatives can enhance the cohesion and mechanical strength of the tablet. Conducting trials to determine the optimal binder concentration is essential to balance tablet hardness and compressibility.

Moreover, controlling the compression force during the tablet production process is vital. Over-compression can lead to stressed tablets that tend to cap or laminate. Ensuring proper adjustment of the pre-compression and main compression forces on the tablet press can reduce the risk of mechanical stresses causing tablet defects.

Granule size uniformity also plays a significant role in preventing capping and lamination. Fine powders can lead to air entrapment within the tablet matrix, causing weak points that result in capping. Employing granulation techniques to achieve a uniform particle size distribution can mitigate this problem.

Lastly, the drying process in wet granulation must be carefully controlled. Overly dried granules can become brittle and less cohesive, while under-dried granules can be too plastic. Both conditions contribute to capping and lamination issues, making careful monitoring of drying parameters imperative.

Mottling and Color Variations

Aesthetics are crucial in tablet production, and mottling or color variations can significantly affect consumer perception. Mottling, an uneven distribution of color on the tablet surface, often results from improper mixing, incompatible excipients, or temperature fluctuations during processing.

Achieving a homogenous mix of the active pharmaceutical ingredient (API) and excipients is fundamental. Utilizing high-shear mixers or tumbling blenders can ensure uniform distribution of all components. Establishing robust mixing protocols and conducting batch consistency tests can prevent color variations effectively.

Another strategy involves the selection of compatible colorants. Some colorants might interact with other formulation components, leading to uneven color distribution. Conducting compatibility tests during the formulation development stage can help identify and mitigate potential issues.

Furthermore, controlling processing temperatures is critical. Temperature-dependent colorants can discolor if the processing temperatures fluctuate significantly. Maintaining a stable temperature environment, especially during blending and compression, can avert mottling problems.

Coating processes are also prone to color variations. Ensuring a uniform coating application through precise control of spray rates, drying temperatures, and tablet bed rotation speeds can lead to consistent tablet appearance. Additionally, performing regular calibration and maintenance of coating pharma machinery is essential to maintain high-quality tablet aesthetics.

Chipping and Cracking

Chipping and cracking detract from the tablet's visual appeal and integrity, often arising from physical stress or poor formulation design. This issue can lead to increased mechanical stress during handling, packaging, and transportation, ultimately affecting the tablet's efficacy.

A fundamental approach to preventing chipping and cracking is to optimize the tablet's hardness and friability. Proper adjustments to the compression force and the use of adequate binders can enhance the tablet's mechanical strength. Conducting hardness and friability tests during the formulation development phase helps establish the optimal balance to minimize chipping and cracking risks.

Incorporating plasticizers, like polyethylene glycol (PEG) or glycerin, can enhance the flexibility of the tablet matrix, reducing susceptibility to chipping. However, careful consideration of their effects on dissolution and stability is essential to avoid compromising overall tablet quality.

Another factor involves minimizing physical stress during the manufacturing process. Ensuring smooth transfer and handling of tablets throughout the production line can prevent physical damage. Using coated punches and dies can also reduce abrasive interactions that contribute to chipping.

Lastly, thorough quality control checks and batch testing are paramount. Identifying chipping and cracking issues early in production allows for immediate adjustments and ensures the consistent quality of the finished product. Implementing robust quality control measures helps maintain product integrity and consumer trust.

In conclusion, troubleshooting tablet die issues requires a meticulous approach, blending analytical insights with practical interventions. By addressing problems like die sticking, weight variations, capping, mottling, and chipping through targeted measures, manufacturers can significantly enhance product quality and process efficiency. Regular maintenance, rigorous quality control, and optimized formulations are pillars of a robust tablet production process.

Understanding and mitigating these common die issues is integral to maintaining the efficiency and integrity of tablet manufacturing. With continuous monitoring and adapting to evolving manufacturing challenges, producers can deliver high-quality tablets that meet rigorous industry standards. The insights provided in this article serve as a comprehensive guide for those navigating the complexities of tablet production, ensuring their journey towards achieving flawless tablets is well-informed and strategically sound.

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